Carbonation system and method

ABSTRACT

The water carbonation method and apparatus of the present invention consists of a square mixer within a carbonated chamber. The mixer is partially filled with water. Carbon dioxide is then added above the level of water. A rotating member attached to the mixing motor then mixes the water and carbon dioxide to from a carbonated solution. Varying the time for which the carbonation operation is carried on may vary the degree of carbonation. After the specified carbonation cycle, excess carbon dioxide is then relieved through an exhaust solenoid and the remaining carbonated solution is released through the dispensing solenoid into a

TECHNICAL FIELD

[0001] The present invention relates to a system and method ofcarbonating liquids such as in association with a water cooler. Moreparticularly, the present invention is directed to a carbonation systemand method that allows effective carbonation to a desired degree.

BACKGROUND OF THE INVENTION

[0002] Various methods of carbonating water are known in the prior art.One method, involves injecting carbon dioxide into the water. Thisinjection of carbon dioxide forms bubbles that float up through thewater. Carbon dioxide in the bubbles is then absorbed into the water.This method has been widely used in relatively small carbonatingapparatuses for home use and operable for dispensing carbonated water inquantities sufficient to form one drink. The main problem with thismethod is that it is only effective if relatively high pressures areused in the carbonation chamber.

[0003] Another method involves spraying or atomizing the water into anatmosphere of carbon dioxide gas. In this method, a carbonation chamberis pre-filled with carbon dioxide and water is added to the chamber byspraying. Thus, carbon dioxide is dissolved into the water droplets, thewater droplets then carry the carbon dioxide into the body of water. Theproblem with this method is that a long period of time is required toachieve sufficient carbonation and it also requires a relatively highlevel of pressurization in the carbonation chamber.

[0004] Another method, described in U.S. Pat. No. 4,719,056, partiallyfills a chamber with water, adds carbon dioxide gas in the space abovethe water and then agitates the water with a horizontal rotating paddlehaving blades that project above the water into the carbon dioxide gasspace.

[0005] Consequently, there is a need for a carbonation system andmethod, which is faster and more efficient. There is also a need for aliquid cooler, such as a water cooler, which includes the capacity tocarbonate liquid beverages. It would also be advantageous to allowcarbonation of a liquid to a desired degree, and to allow carbonation ofsuch beverages without requiring high pressures to be used in thecarbonization chamber.

SUMMARY OF THE INVENTION

[0006] The system and method disclosed in the present invention comprisea carbonation chamber partly filled with water. Carbon dioxide is thenadded above the level of water. A rotating member then mixes the waterand carbon dioxide to form a solution. This method causes the water andcarbon dioxide to form a solution of carbonated water.

[0007] The carbonated water cooler of the present invention furthercomprises a unique valve system for transferring and mixing of fluids inthe desired sequence and volumes. Further aspects and advantages of theinvention will become apparent upon a reading of the descriptionassociated with an embodiment thereof, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a block diagram of the carbonated water cooler accordingto the present invention;

[0009]FIGS. 2A and 2B are front and side partial cross sectional viewsrespectively, of one embodiment of the carbonation system according tothe present invention;

[0010]FIGS. 3A and 3B are front and side views of a second embodiment ofthe carbonation system of the present invention;

[0011]FIG. 4 is an enlarged cross-sectional view of a pressure regulatorused with the carbonation system;

[0012]FIG. 5 is an enlarged cross-sectional view of a pressure switchused with the carbonation system;

[0013]FIG. 6 is an enlarged cross-sectional view of a carbonationchamber used with the carbonation system;

[0014]FIG. 6A is an enlargement of a portion of FIG. 6, illustrating thedetails of the liquid inlet and carbonated liquid dispensing valves;

[0015]FIG. 7 is an enlarged partial cross-sectional view of thecarbonation chamber used with the carbonation system;

[0016]FIG. 8 is an enlarged cross-sectional view of a solenoid used withthe liquid inlet and carbonated liquid dispensing valves;

[0017]FIG. 9 is a side view of the carbonation chamber and associatedcomponents;

[0018]FIG. 10 is a cross-sectional view of the carbonation chamber withthe internal components removed;

[0019]FIG. 11 is a schematic view illustrating the fluid connectionsbetween some of the carbonation system components; and

[0020]FIG. 12 is an enlarged cross sectional view of a gas silencer usedwith the carbonation system.

DETAILED DESCRIPTION OF THE INVENTION

[0021] Turning now to FIG. 1, there is shown a block diagram of thecarbonation process according to one embodiment of the presentinvention. The carbonation system and method may be used with existingor originally manufactured water coolers or other beverage dispensers orin other applications as desired. The system allows existing watercoolers to be easily retrofitted to allow selective carbonation.Similarly, the system could be used with other liquid dispensers in asimilar fashion. In the example of a water cooler, water from a tank iscooled in the cooler 3 until dispensing is desired. Upon a userrequesting a carbonated drink, the system is initiated by a userdepressing a switch or another control mechanism. A control system 5operates the system to cause the opening of a water filling solenoid 8.The control system 5 may comprise an electronic control circuit board 4and an electrical transformer 2 for conversion of power to control thecarbonation system. The solenoid 8 selectively allows water, or anotherliquid, to enter an upper part of the mixing assembly unit orcarbonation chamber 6 for about 6 seconds. A vent 142 in the carbonationchamber 6 permits air in the unit to be vented to the atmosphere whilethe carbonation chamber 6 is being filled with water and permits air toenter when carbonated liquid is dispensed from carbonation chamber 6.Once the carbonation chamber 6 is filled to the appropriate level 17with water, the water filling solenoid 8 is then closed to preventadditional water from entering the carbonation chamber 6, or water fromre-entering the conduit to the cooler 3. If the solenoid 8 were notclosed, pressure in the carbonation chamber 6 could force water out ofthe carbonation chamber 6.

[0022] Next, the carbon dioxide filling solenoid valve 20 opens,allowing carbon dioxide from a carbon dioxide storage cylinder 14 toenter the carbon dioxide connecting tube 16 and then to the carbonationchamber 6 via a pressure regulator 18. The pressure regulator 18 can beselectively adjusted to provide for the introduction of the desiredamount of carbon dioxide. A pressure control switch 22 senses the gaspressure in the carbonation chamber 6, so that when it reaches apredetermined level or volume, gas solenoid valve 20 is de-energized tostop the flow of carbon dioxide gas into the carbonation chamber 6. Apressure safety valve 24 can be provided to automatically reduceover-pressure (˜10 bar) in carbonation chamber 6. A non-return valve 26may also be provided if desired, which acts to stop carbon dioxide orliquid from re-entering tube 16 or being forced out of the carbonationchamber 6 due to pressure in the carbonation chamber 6.

[0023] In this manner, carbon dioxide is introduced in the space abovethe level 17 of the liquid, such as water, disposed in the carbonationchamber 6. A mixer, schematically shown at 13, may be provided inassociation with a mixing motor 12, within the carbonation chamber 6.The mixing motor 12 is selectively energized to activate the mixer 13;which mixes the carbon dioxide into the water or other liquid. Theaction of the mixer 13 forces the carbon dioxide gas in the space abovethe water level down into the water. As will hereafter be described inmore detail, the configuration of the mixer 13 and the shape of thecarbonation chamber unit 6 allow for intense agitation such that theliquid is uniformly carbonated. Further, the degree of carbonation maybe selectively varied by varying the time for which the mixer 13 isdriven and/or by varying the amount carbon dioxide gas introduced bycontrolling the pressure of the atmosphere containing carbon dioxide inthe space in the carbonation chamber 6 above the water level 17.

[0024] As an example, the carbon dioxide gas filling solenoid 20 opensand after approximately 0.5 seconds, operation of the mixing motor 12 isinitiated. Mixing and carbonation may be performed for about sevenseconds for producing about 1.9 dl of a more highly carbonated beverage(6 gr/l), or about four seconds for producing about 1.9 dl of a lightlycarbonated beverage (4 gr/l). As carbonation progresses, the waterabsorbs gas from the space above the water level 17 in the carbonationchamber 6 so that gas pressure reduces. This pressure reduction issensed by the pressure control switch 22, which then acts to open thegas solenoid valve 20 and allow more carbon dioxide into the carbonationchamber 6, thereby maintaining a proper pressure of carbon dioxide inthe carbonation chamber 6. Subsequently, the control system 5 mayintroduce a damping period of about two seconds as an example, allowingthe carbonated liquid to settle somewhat in the carbonation chamber 6.After the damping period, a cut off or exhaust solenoid valve 28 is thenopened to release any excess carbon dioxide through a silencer 30,thereby relieving pressure in the carbonation chamber 6. Once pressureis relieved, the carbonated liquid dispenser solenoid 10 is operated torelease the carbonated liquid mixture into a cup 7.

[0025] An embodiment of the carbonation system as shown in FIG. 1 isshown in FIGS. 2A and 2B. The carbonation system 32, may be used inconjunction with a water cooler as an example, and thus may be designedto be selectively coupled to a cooler for use. In such an embodiment, aseparate housing 42 may be provided, which may be configured toaesthetically match any type of water cooler, or could be otherwiseconfigured. Alternatively, the carbonation unit 32 could be formedintegral with a water cooler such as shown in the embodiment of FIGS. 3Aand 3B, so as to make both carbonated and non-carbonated liquidsavailable in an originally manufactured unit. In the embodiment of FIG.2, the housing 42 may further be of a size to allow a significantlylarger carbon dioxide tank to be housed therein, such that replacementof the tank is only required at relatively longer intervals depending onuse. The carbon dioxide storage in previous apparatus has been limitedin size, requiring special containers and more maintenance andreplacement, whereas the size of housing 42 allows standard size carbondioxide tanks or containers to be used. For example, the housing 42 mayhold a 5 kg carbon dioxide cylinder 14 inside. The housing 42 may beconstructed of metal, plastic or other suitable materials. The housing42 may have multiple openings formed therein to allow the lead electriccable and water junction pipe to pass through and connect to appropriatesystems within housing 42. Additionally, the housing 42 makes it easy tomount various components such as the carbonation chamber 6, the silencer30, the control circuit board 4, as well as the carbon dioxide cylinder14. There is also a cup holding area, which contains a drip tray 38 anddrip tray lid 36. A control panel 41 may be provided on the front of thehousing 42, comprising a plurality of user controlled buttons, switchesor the like for selective operation of the carbonation system. Forexample, on control panel 41 may be provided means for increasing anddecreasing the amount of carbonation within the carbonated water, suchas switches.

[0026] An alternative embodiment of an integrated carbonation system isset forth in FIGS. 3A and 3B, the system being shown generally at 110.Carbonation system 110 includes a housing 112, a carbonated liquiddispenser 114, a cold liquid dispenser 116 and a warm liquid dispenser118. Having the capability to dispense cold, warm and carbonated wateras an example, increases the utility of carbonation system 110 andallows for servicing a variety of consumer's needs. Carbonation system110, preferably also includes a control panel similar to the embodimentof FIG. 2, with means for increasing and decreasing the amount ofcarbonation within the carbonated water, such as switches 120 and 122for increasing or decreasing the carbonation level. It is alsopreferred, although not necessary, to include a water temperaturedisplay 128. Furthermore, in this embodiment, there is provided anindicator panel 130 which provides means for indicating when the systemis operating, when water is being heated or cooled, or when there is acarbonation error, such as if no water or liquid is introduced into thechamber, the system is out of carbon dioxide or if no pressure is formedin the mixing chamber for example.

[0027] As shown in FIG. 3B, this embodiment also preferably includes apressure gauge 124 for indicating the pressure within carbonationchamber 6. As with embodiment 32, embodiment 110 includes an accesspanel 126 to allow for access to the components of carbonation system110, within housing 112. In operation, carbonation system 110 mayoperate similarly to system 32 with the addition of elements for coolingand heating non-carbonated and or carbonated water or other liquids.

[0028] Turning to FIG. 4, the pressure regulator 18 as schematicallyshown in FIG. 1 is shown in more detail. The pressure regulator 18allows for fast and easy installation and reliable operation. In apreferred form, the pressure regulator 18 will perform predeterminedfunctions, comprising the supply of a predetermined amount of carbondioxide gas at a predetermined rate throughout the mixing cycle, such asapproximately 2 gr./sec. Further, the pressure regulator 18 maintains astable and substantially uniform pressure (5 to 5.5 bar) on an output orsecondary side 49, irrespective of pressure change on the input orprimary side 47, which may, for example, occur in the case of a lowcarbon dioxide cylinder. The pressure regulator in one embodimentcomprises a moveable cone valve 46, preferably fabricated from amaterial such as polypropylene, closing on a circular opening within theregulator 18. The flow of gas through the regulator 18 proceeds from thegas supply through a conduit coupled to the primary side 47 to asecondary side 49 through valve 46. The secondary side is then coupledto the carbonation chamber 6 through a manifold 140.

[0029] Pressure regulator 18 has a two piece housing 43 with a highpressure inlet 47 and a low pressure outlet 49. A flexible diaphragm 44,captured between the two parts of housing 43, divides the interior ofhousing 43 into a gas portion 57 and a spring portion 37. Spring 55within the spring portion 37 of housing 43 exerts a first or springforce on diaphragm 44 while gas pressure in gas portion 57 of housing 43exerts a second force or gas force on diaphragm 44 that is opposite ofthe spring force. A two piece actuating assembly 53 is placed on bothsides of diaphragm 44. A valve seat 33, which fits into high pressureinlet 47, slidingly engages a boss 53 a extending from actuatingassembly 53. Valve seat 33 has at least one aperture 34 to permit gasflow from high pressure inlet 47 into the gas portion 57 of housing 43.The movable cone valve 46 fits within valve seat 33 and is biased to aclosed position by spring 51. A removable bronze sinter filter 50 fitsbetween a removable inlet fitting 47 a and valve seat 33. Movable valve46 is sized and shaped to fit through high pressure inlet 47 when inletfitting 47 a has been removed. Movable valve 46 has a needle portion 46a that extends from the movable valve 46 and into contact with actuatingassembly 53. When the pressure of low pressure gas in gas portion 57 ofhousing 43 drops, the gas force on diaphragm 44 will drop below thespring force on diaphragm 44 allowing spring 55 to move actuatingassembly 53 towards the high pressure inlet 47. The actuating assembly53 then pushes on needle portion 46 a and move movable valve 46 to anopen position, against the force of spring 51. Carbon dioxide gas thenflows through apertures 34 in movable valve 33. The restricted openingthrough which the gas flows reduces the gas pressure to the desired 5 to5.5 bar. An adjuster 35 is provided at the top of housing 43 to adjustthe spring force on diaphragm 44. The output 49 of pressure regulator 18is connected to carbon dioxide gas solenoid valve 20.

[0030] Further, the pressure regulator 18 is also easy to install andinexpensive. The elements of the pressure regulator 18 may be fabricatedsimply from a material such as brass, and the components are easilyassembled using simple fittings. Pressure regulation is easilycalibrated by adjustment of the actuating assembly 53 or othercomponents as desired, such as the cone shaped valve 46. Installation ofthe movable valve 46 is easily performed by a screw fitting 47 a andsealing on the primary side is ensured by an O-ring 48 and the valveseat 33, allowing the movable valve 46 to be screwed in by hand.

[0031] The pressure control switch 22 as shown in FIG. 5, sensespressure in the carbonation chamber 6 in excess of a predeterminedpressure, such as around 3 bar for example. Pressure switch 22 has a twopiece housing 63 having a pressure inlet 61 at one end, connected via amanifold 140 (See FIG. 11) to carbonation chamber 6, and a flexiblediaphragm 54 at the other end sealing gas pressure within housing 63.Pressure within housing 63 is exerted on diaphragm 54, causingdeformation of diaphragm 54. Deformation of the diaphragm 54, in turnpushes a plunger 65, captured between the two pieces of housing 63,against a spring biased arm 56. Arm 56 is part of a micro-switch 58. Arm56 presses against another plunger 67 in switch 58 and causes electricalcontacts within switch 58 to change position. Preferably, switch 58 ismounted on a PCB board 60. The configuration of pressure switch 22 makesthe switching force independent of the magnitude of the pressure of thegas.

[0032] In an embodiment of the invention, the safety valve 24 andnon-return valve 26 are built into one unit. The safety valve 24 is setto react at a predetermined pressure, such as 10 bars for example. Thenon-return valve 26 prevents the back-flow of liquids and/or carbondioxide into the pressure controller in case the carbonation chamber 6remains under pressure while the primary pressure ceases for somereason, such as if the carbon dioxide cylinder 14 becomes unattached.

[0033] Also, there may be provided a silencer 30, which is meant tobrake the high speed of gas as it is released by the exhaust valve 28and to separate the carbon dioxide and liquid. Operation of the unit isthen relatively silent and aesthetically pleasing. The carbon dioxideenters the filter, expands, and then exits through bore holes on theupper part of the silencer 30. Water is then collected at the bottom ofthe silencer 30 and discharged through a plastic pipe to the drippingtray 38.

[0034] An embodiment of the carbonation chamber 6 is depicted in FIGS.6, 6A and 7, and is symmetrically designed for ease of manufacture. Inthis configuration, the water filling and the discharge of carbonatedwater is realized with a water inlet valve 74 and a water dispensingvalve 75 that have identical parts and a common valve spring 72. Asshown in FIGS. 6, 6A and 7, water inlet valve 74 introduces water intoan upper part of carbonation chamber 6. There are identical flexibleseals 78, valve arms 80, flexible seals 82, and water filing anddraining solenoids 8, 10. This symmetrical design allows for easyproduction and assembling of parts. Also, a tight internal valve area iscreated by adhering the water filling and draining valves 74, 75 to thecarbonation chamber 6. The adhesive may be specially designed forpolycarbonate material. This adhesive ensures a strong bond with thepolycarbonate material, thus the binding strength is nearly identicalwith that of the basic material. Carbonation chamber 6 has two brackets9 for holding solenoids 8, 10.

[0035] Each water or liquid valve 74, 75 has a flexible seal 78 thatseals against an inner surface of the carbonation chamber 6 about anaperture 81 formed through a wall of carbonation chamber 6. The aperture81 can extend both inwardly and outwardly from the wall of carbonationchamber 6, forming a tube-like extension. A valve housing 76 is attachedto the outward extension of aperture 81. Valve housing 76 may be formedas part of carbonation chamber 6. A movable valve sleeve 79 fits withinthe tube-like extension of aperture 81 and has a plurality ofcircumferentially spaced apertures 84 formed through an inner end.Apertures 84 permit the flow of liquid through the water valve 74, 75when valve sleeve 79 lifts flexible seal 78 away from the adjacentsurface of carbonation chamber 6.

[0036] Spring 72 biases flexible seal 78 and valve sleeve 79 to a closedposition. Preferably, water inlet valve 74 is positioned verticallyabove water dispensing valve 75 so that a single spring 72 can be usedto bias both valves 74, 75 to the closed position.

[0037] Valve housing 76 has an aperture 83 formed in its side surface.Valve arm 80 is pivotally connected to valve housing 76 and extendsthrough aperture 83. A flexible sleeve 82 fits around valve arm 80 toseal valve arm 80 to aperture 83. A pusher rod 94 on solenoid 8, 10pushes valve arm 80 when solenoid 8, 10 is energized, causing valve arm80 to pivot, lifting valve sleeve 79 and flexible seal 78 to permit flowof liquid through water valve 74, 75.

[0038] Further, the carbonation chamber 6 of FIGS. 6 and 7 may be madeof transparent polycarbonate, giving it a pleasing aesthetic appearance.This transparent material also allows the user to view the contents ofthe carbonation chamber 6 and therefore denote more rapidly if there isa malfunction or problem with the carbonation process. However, thecarbonation chamber 6 needs to withstand a predetermined maximumpressure, such as an approximately 5.5 bar operating pressure, and itmay therefore have bracing ribs or reinforcing supports 90 provided toincrease the structural integrity of the unit. These ribs 90 add supportto the outer structure of the carbonation chamber 6, allowing it to bearthe maximum operating pressure. Pressure resistance of the bracing ribs90 may provide integrity well beyond the maximum operating pressure toensure safety.

[0039] The partial cross-section shown in FIG. 7 illustrates thecarbonation chamber 6 and a vent/check valve 68. Vent/check valve 68vents air from carbonation chamber 6 via exhaust 142 while thecarbonation chamber 6 is being filled with water; prevents water and/orcarbon dioxide gas from being vented from carbonation chamber 6 whenpressurized with carbon dioxide gas; and permits air to flow intocarbonation chamber 6 when carbonated water is being dispensed.Vent/check valve 68 includes a housing 69, which may be formed as partof carbonation chamber 6. Housing 69 extends inwardly from an apertureformed in a wall of carbonation chamber 6. A ball seat 62 fits intohousing 69. A ball cage 66 with a floating ball 64 therein is attachedto a lower end of housing 69. As water is introduced into carbonationchamber 6, air vents through vent/check valve 68 until floating ball 64rises and seats against ball seat 62 closing vent/check valve 68. Thisprevents discharge of carbon dioxide gas when carbonation chamber 6 ispressurized with carbon dioxide gas. The water level in carbonationchamber 6 is controlled by the vent/check valve 68.

[0040] Carbonation chamber 6 is filled with water to the predeterminedwater level 17, which is set for a 4:1 ratio of water volume to thecarbon dioxide gas volume above the water volume. This ratio ensuresboth economical use of the water and the discharge of a minimum amountof waste water during release of the gas pressure after mixing.

[0041] Carbonation chamber 6 has a rectangular design, and, preferably,a square design, as shown in FIGS. 6, 7 and 10. Therefore, when mixingis done with a horizontally rotatable bladed stirrer 70, the squaredesign of carbonation chamber 6 creates more agitation, thus mixing thesolution faster and more thoroughly. Overall, the carbonation chamber 6consists of upper 6 a and a lower 6 b parts (See FIG. 10), with aprofiled silicon seal 6 c sealing the two parts. The upper and lowerparts 6 a, 6 b of the carbonation chamber 6 are connected by threadedbars and secured with nuts. The same threaded bars are used toresiliently attach the entire carbonation chamber 6 to the housing 42 ofthe carbonated water cooler 32.

[0042] Preferably, bladed stirrer 70 has a plurality of spaced apartblades 71 extending from a horizontal shaft. Bladed stirrer 70 isconnected to motor 12 by gear 72 driven by a belt 73 that is driven by asmaller gear 74 connected to motor 12 (See FIG. 9).

[0043] The water filling and draining solenoids 8, 10 are illustrated ina de-energized position in FIG. 8. Each solenoid 8, 10 has a movablecylindrical plunger 106 having a cone shape 106 a at one end. Themovable plunger 106 is positioned within a housing 98 that encloseselectrical coils 102. The electrical coils are connected to the controlsystem by an electrical connector 104. An end plate 96 is attached toone end of housing 98. End plate 96 has a cone shaped aperture 96 a,which has a complementary size and shape to the conical end 106 a ofplunger 106. A pusher rod 94 is attached to the conical end 106 a ofplunger 106 and extends through conical aperture 96 a. A stop ring 92 isattached to the free end of pusher rod 94 to prevent pusher rod 94 frompassing through conical aperture 96 a. A spring 100 (See FIGS. 6, 6A)biases plunger 106 to the de-energized position (shown in FIG. 8).Energizing coils 102 causes plunger 106 to move in the direction ofarrow 107 and extends pusher rod 94 further from end plate 96. The waterfilling and draining solenoids 8, 10 were specially developed for theamount of space available in the carbonation system 32. They may be madeof steel, with tension-relieving heat treatment and zinc passivationsurface protection. Therefore, the solenoids can withstand normaloperating procedures of 24V DC without over-heating for repeated cycles.The cone seal design of the magnetic element and case ensure propertravel of the solenoid 8, 10.

[0044] A gas manifold 140 (See FIGS. 6 and 11) is provided to connectthe pressure sensor 22, the carbon dioxide gas inlet solenoid valve 20,the pressure safety valve 24, the non-return valve 26 and the exhaustgas solenoid valve 28 to the carbonation chamber 6. The pressure safetyvalve 24 and non-return valve 26 are, preferably, both contained in afitting 144 connected to the top of gas manifold 140. Also shown in FIG.11 are the inlet 141 to the water inlet valve 74, the vent connection142 for the vent/check valve 68 and the gas inlet 143 to the carbonationchamber 6 from gas manifold 140. The low pressure gas outlet 49 frompressure regulator 18 is connected to carbon dioxide gas inlet solenoidvalve 20, which is then connected to an inlet of gas manifold 140. Afirst outlet of gas manifold 140 connects to the carbonation chamberinlet 143. A second outlet of gas manifold 140 connected to pressuresensor 22. A third outlet of gas manifold 140 is connected to exhaustgas solenoid valve 28.

[0045]FIG. 12 shows a cross section of gas silencer 30. Silencer 30 isformed from a two piece housing, an upper housing 30 a and a lowerhousing 30 b. Upper housing 30 a has two inlets, a water inlet 132,which receives excess water from carbonation chamber 6 via ventconnection 142, and a gas inlet 131, which receives vented carbondioxide gas from exhaust solenoid valve 28. The upper housing includesat least one internal cavity 136 filled with a twisted polyester filter135. Preferably, the upper housing is divided into a central internalcavity 136, which receives the vented gas via gas inlet 131 and an outerinternal cavity 137, which surrounds the central internal cavity 137 andreceives the excess water via water inlet 132. The twisted polyesterfilter 135 may fill both cavities 136, 137, or only the central internalcavity as shown in FIG. 12. A plurality of radially extendingcircumferentially spaced apart vanes 134 are provided in lower housing30 a positioned around an outlet 133. Outlet 133 drains to drip tray 38.Vanes 134 support filter 135. In operation, excess water and ventedexcess gas enter the silencer 30 through inlets 132 and 131 respectivelyand then mix and depressurize (expand) in the cavities 136, 137 wherethe twisted polyester filter 135 is positioned. Water then exits thesilencer 30 by gravity through outlet 133 to drip tray 38.

[0046] Production of carbonated water is done according to the followingsequence:

[0047] After the cycle is initiated by operating one of the carbonationlevel switches, high carbonation or low carbonation, water inlet valvesolenoid 8 is energized for about 6 seconds opening water inlet valve 74filling carbonation chamber 6 to the predetermined level 17. (Thecarbonation chamber 6 typically fills to the predetermined level inabout 4 seconds.).

[0048] The carbon dioxide gas filling solenoid valve 20 is opened,allowing carbon dioxide gas to flow into the carbonation chamber 6,pressurizing the carbonation chamber 6 to about 5 bar.

[0049] About 0.5 second after carbon dioxide gas filling solenoid valve20 opens, mixing motor 12 operates to rotate bladed mixer 70, providedpressure sensor 22 detects gas pressure in carbonation chamber 6.

[0050] Mixing motor 12 operates for about 7 second for high carbonationand about 4 seconds for low carbonation.

[0051] While mixing motor 12 is operating, additional carbon dioxide gasis added as pressure sensor 22 detects a drop in gas pressure.

[0052] After the mixing time (7 seconds or 4 seconds) completes, motor12 is stopped and carbonation chamber 6 is allowed to settle for about 2seconds.

[0053] After the 2 second delay, exhaust solenoid valve 28 is energized,relieving the gas pressure from the carbonation chamber 6 throughsilencer 30.

[0054] After the pressure is relieved from carbonation chamber 6, waterdispensing valve 75 opens draining carbonated water into a 2 dlcontainer in about 6 seconds.

[0055] The overall cycle time is about 24 seconds for high carbonationand 21 seconds for low carbonation.

[0056] Although the principles, preferred embodiments and preferredoperation of the present invention have been disclosed in detail herein,this is not to be construed as being limited to the particularillustrative forms disclosed. It will thus become apparent to thoseskilled in the art that various modifications of the preferredembodiments herein can be made without departing from the spirit orscope of the invention as defined by the appended claims.

1. A carbonation apparatus comprising: a rectangular carbonationchamber; a means for partially fining the carbonation chamber with waterto a predetermined level; a means for introducing carbon dioxide gasinto the carbonation chamber above the water; a pressure regulatorregulating the pressure of carbon dioxide gas being introduced into thecarbonation chamber, the pressure regulator comprising a housing havinga high pressure inlet and a low pressure outlet; a flexible diaphragmdividing an interior of the housing into a gas portion and a springportion; a spring within the spring portion of the housing, the springexerting a first force on the diaphragm, carbon dioxide gas within thegas portion of the housing exerting a second force on the diaphragmopposite the first force; a valve seat within the housing and in fluidcommunication with the high pressure inlet, the valve seat having atleast one outlet aperture in fluid communication with the gas portion ofthe housing; a movable valve, within the valve seat, biased to a closedposition, the movable valve having a cone shaped portion engaging thevalve seat and a needle shaped portion extending from the cone shapedportion, the cone shaped portion being operatively connected to thediaphragm, whereby when the first force is greater than the secondforce, the movable valve is moved to an open position; a pressure switchsensing pressure of carbon dioxide gas in the carbonation chamber, thepressure switch comprising: a pressure housing in fluid communicationwith the carbonation chamber, a flexible diaphragm sealing an end of thepressure housing; and an electrical switch having: a set of contactsmovable between an open position and a closed position; and an armbiased to a first position, the arm being operably connected to theflexible diaphragm, whereby an increase of pressure in the pressurehousing causes the flexible diaphragm to move the arm to a secondposition, movement of the am from one position to the other positioncausing the set of contacts to move between the open position and theclosed position; a means for, mounted within the carbonation chamber,agitating the water to mix carbon dioxide gas into the water; a meansfor relieving gas pressure from the carbonation chamber prior todispensing carbonated water from the carbonation chamber; a mean forsilencing noise from the gas pressure relieved from the carbonationchamber, the means for silencing noise comprising: a housing having agas inlet, a water inlet, an outlet, two internal cavities, and a filterpositioned within at least one cavity, a first cavity beingcommunication with the gas inlet and a second At being communicationwith the water inlet, both cavities being communication with the outlet,the gas inlet receiving gas being relieved from the carbonation chamber,the water inlet receiving water being vented from the carbonationchamber, the filter being positioned in at least the first cavity; and ameans for dispensing carbonated water from the carbonation chamber, themeans for partially filing including an inlet water valve and the meansfor dispensing including a dispensing water valve, a single springbiasing both water valves to a closed position, the means for partiallyfiling the carbonation chamber, and the means for dispensing water fromthe carbonation chamber including a solenoid operator, the solenoidoperator comprising: a housing; a movable cylindrical plunger having aconical end, the plunger being movable between a first position and asecond position, the plunger being positioned within the housing, apusher attached to the conical end of the plunger, the pusher andplunger being biased to the first position; an end plate attached to anend of the housing, the end plate having a conical aperturetherethrough, the shape and size of the conical aperture beingcomplementary to the shape and size of the conical end of the plunger,and an electrical coil surrounding at least a portion of the plunger,the electrical coil being housed within the housing, whereby applicationof an electrical curd to the electrical coil causes the plunger to movetom the first position to the second position, the means for partiallyfilling the carbonation chamber with water introducing the watervertically above where the means for dispensing carbonated water fromthe carbonation chamber removes the carbonated water from thecarbonation chamber.
 2. A method for carbonating water comprising thesteps of: selecting one of a first carbonation level and a secondcarbonation level; partially filling a rectangular carbonation chamberwith water to a pre-determined level; introducing carbon dioxide gasinto the carbonation chamber above the water; about 0.5 seconds afterthe step of introducing carbon dioxide begins, when the firstcarbonation level is selected, agitating the water for about 7 secondsto mix carbon dioxide gas into the water, and when the secondcarbonation level is selected, agitating the water for about 4 secondsto mix carbon dioxide gas into the water; maintaining the pressure ofthe carbon dioxide gas in the carbonation chamber while agitating thewater; about 2 seconds after the step of agitating the water completes,relieving gas pressure from the carbonation chamber, and dispensingcarbonated water from the carbonation chamber.
 3. The method accordingto claim 2, further comprising: silencing the gas pressure beingrelieved from the carbonation chamber.
 4. The method according to claim3, further comprising: venting excess water from the carbonationchamber; and mixing the vented excess water and the relieved gas duringthe step of silencing.
 5. A carbonation apparatus comprising: arectangular carbonation chamber; a means for partially filling thecarbonation chamber with water to a pre-determined level; a means forintroducing carbon dioxide gas into the carbonation chamber above thewater; means for, mounted within the carbonation chamber, agitating thewater to mix carbon dioxide gas into the water; and a means fordispensing carbonated water from the carbonation chamber, the means forpartially filing and the means for dispensing including combined filingand dispensing valves.
 6. The carbonation apparatus according to claim5, wherein the water partially filing the carbonation chamber isintroduced into an upper part of the carbonation chamber.
 7. Thecarbonation apparatus according to claim 5, further comprising: a meansfor venting air from the carbonation chamber while the carbonationchamber is being partially filled with water.
 8. The carbonationapparatus according to claim 5, further comprising: a source of carbondioxide gas; and a pressure regulator regulating the pressure of thecarbon dioxide gas introduced into the carbonation chamber.
 9. Thecarbonation apparatus according to claim 8, wherein the pressureregulator regulates the pressure of the carbon dioxide gas to about 5bar.
 10. The carbonation apparatus according to claim 5, furthercomprising: a pressure switch sensing pressure of carbon dioxide gas inthe carbonation chamber.
 11. The carbonation apparatus according toclaim 10, wherein the means for introducing includes a gas valvecontrolling the introduction of carbon dioxide gas into the carbonationchamber, the gas valve being actuated by the operation of the pressureswitch.
 12. The carbonation apparatus according to claim 5, wherein thecarbonation chamber is transparent.
 13. The carbonation apparatusaccording to claim 12, wherein the carbonation chamber is formed frompolycarbonate.
 14. The carbonation apparatus according to claim 13,wherein the carbonation chamber has a plurality of reinforcing supportsabout the exterior of the carbonation chamber.
 15. The carbonationapparatus according to claim 5, further comprising: a housing, thecarbonation chamber being resiliently mounted within the housing. 16.The carbonation apparatus according to claim 5, wherein the means forpartially filing is a solenoid operated valve.
 17. The carbonationapparatus according to claim 5, wherein the means for dispensing is asolenoid operated valve.
 18. The carbonation apparatus according toclaim 5, wherein the means for agitating includes a rotatable paddlehaving a plurality of blades thereon.
 19. A carbonation apparatuscomprising: a rectangular carbonation chamber; a means for partiallyfilling the carbonation chamber with water to a pre-determined level; ameans for introducing carbon dioxide gas into the carbonation chamberabove the water; a means for, mounted within the carbonation chamber,agitating the water to mix carbon dioxide gas into the water; and ameans for dispensing carbonated water from the carbonation chamber,wherein, when the carbonation chamber is filled to the pre-determinedlevel, the volume ratio of liquid to gas is about 4 to
 1. 20. Acarbonation apparatus comprising: a rectangular carbonation chamber; ameans for partially filling the carbonation chamber with water to apre-determined level; a means for introducing carbon dioxide gas intothe carbonation chamber above the water; a means for, mounted within thecarbonation chamber, agitating the water to mix carbon dioxide gas intothe water; and a means for dispensing carbonated water from thecarbonation chamber, the means for partially filling the carbonationchamber with water introducing the water vertically above here the meansfor dispensing carbonated water from the carbonation chamber removes thecarbonated water from the carbonation chamber.
 21. A carbonationapparatus comprising: a carbonation chamber; a means for filling thecarbonation chamber with water to a pre-determined level; a means forintroducing carbon dioxide gas into the carbonation chamber; a means formixing the carbon dioxide gas into the water, and a means for dispensingcarbonated water from the carbonation chamber, wherein at least one ofthe means for filling and the means for dispensing is a water valvecomprising: a flexible seal sealingly engaging an interior surface ofthe carbonation chamber; a valve sleeve movable between a first positionand a second position, the valve sleeve, when in the second position,lifting the flexible seal out of engagement with the interior surface ofthe carbonation chamber, the flexible seal fitting over an interior endof the valve sleeve; and a spring biasing the valve sleeve to the firstposition.
 22. The carbonation apparatus according to claim 21, furthercomprising: a solenoid operatively connected to the valve sleeve, thesolenoid moving the valve sleeve from the first position to the secondposition.
 23. The carbonation apparatus according to claim 21, whereinthe carbonation chamber has a through aperture therein, an aperture sidebeing elongated forming a valve housing the valve sleeve beingpositioned within the aperture, the flexible seal sealing about an innerend of the aperture.
 24. The carbonation apparatus according to claim23, further comprising: a solenoid operatively connected to the valvesleeve, We solenoid moving the valve sleeve from the first position tothe second position; and wherein the aperture side has an operatoraperture therein, a pivotable a extends from the solenoid through theoperator aperture to the valve sleeve, and a flexible sleeve seals thepivotable arm to the operator aperture.
 25. The carbonation apparatusaccording to claim 21, wherein an inner end of the valve sleeve has aplurality of circumferentially spaced apertures therein for passage ofwater therethrough.
 26. The carbonation apparatus according to claim 21,wherein both the means for partially filling and the means fordispensing are water valves, a single spring biasing both valve sleevesto the first position.
 27. A carbonation apparatus comprising: arectangular carbonation chamber; a means for partially filling thecarbonation chamber with water to a predetermined level; a means forintroducing carbon dioxide gas into the carbonation chamber above thewater; a means for, mounted within the carbonation chamber, agitatingthe water to mix carbon dioxide gas into the water; and a means fordispensing carbonated water from the carbonation chamber, the means forpartially filling including an inlet water valve and the means fordispensing including a dispensing water valve, a single spring biasingboth water valves to a closed position.
 28. A carbonation apparatscomprising: a carbonation chamber; a means for filling the carbonationchamber with water to a pre-determined level; a means for introducingcarbon dioxide gas into the carbonation chamber; a means for mixing thecarbon dioxide gas into the water; a means for dispensing carbonatedwater from the carbonation chamber; and a pressure regulator regulatingthe pressure of carbon dioxide gas being introduced into the carbonationchamber, the pressure regulator comprising: a housing having a highpressure inlet and a low pressure outlet; a flexible diaphragm dividingan interior of the housing into a gas portion and a spring portion; aspring within the spring portion of the housing, the sprig exerting afirst force on the diaphragm, carbon dioxide gas within the gas portionof the housing exerting a second force on the diaphragm opposite thefirst force; a valve seat within the housing and in fluid communicationwith the high pressure inlet, the valve seat having at least one outletaperture in fluid communication with the gas portion of the housing; amovable valve, within the valve seat, biased to a closed position, anend of the moveable valve extending beyond the valve seat and beingoperably connected to the diaphragm, whereby when the first force isgreater than the second force, the movable valve is moved to an openposition.
 29. The carbonation apparatus according to claim 28, furthercomprising: a removable filter positioned between the housing highpressure inlet and the movable valve.
 30. The carbonation apparatusaccording to claim 28, further comprising: an inlet fitting removablyattached to the housing high pressure inlet, the movable valve having across-sectional size and shape whereby the movable valve is removablefrom the valve seat when the inlet sing is removed from the housing. 31.The carbonation apparatus according to claim 30, further comprising aremovable filter positioned between the housing high pressure inlet andthe movable valve, the removable filter being captured between a filteraperture in the housing and a filter aperture in the inlet fitting. 32.The carbonation apparatus according to claim 28, further comprising: ameans for adjusting the first force on the diaphragm.
 33. Thecarbonation apparatus according to claim 28, wherein the movable valvehas a cone shaped portion engaging the valve seat.
 34. The carbonationapparatus according to claim 33, wherein the movable valve has a needleshaped portion extending from the cone shaped portion, the needle shapedportion being operatively connected to the diaphragm.
 35. A carbonationapparatus comprising: a source of water; a source of carbon dioxide gas;a pressure regulator having an inlet connected to the source of carbondioxide gas and having an outlet, the pressure regulator reducing thepressure of the source of carbon dioxide gas; a gas inlet valve havingan inlet connected to the outlet of the pressure regulator, and anoutlet; a manifold having an inlet connected to the gas inlet valveoutlet, and plurality of outlets; a carbonation chamber, a first one ofthe manifold outlets being connected to the carbonation chamber; apressure switch having an inlet connected to a second one of themanifold outlets; a gas exhaust valve having an inlet connected to athird one of the manifold outlets and having an outlet; an exhaustsilencer connected to the gas exhaust valve outlet; a water inlet valvehaving an inlet connected to the carbonation chamber, and an outlet; awater outlet valve having an inlet connected to the carbonation chamber;and a mixer within the carbonation chamber.
 36. The carbonation chamberaccording to claim 35, further comprising: a controller for selectivelyoperating: the gas inlet valve; the gas exhaust valve; the water inletvalve; the water outlet valve; and the mixer.
 37. A method forcarbonating water comprising the steps of: partially filling arectangular carbonation chamber with water to a pre-determined level;introducing carbon dioxide gas into the carbonation chamber above thewater; agitating the water to mix carbon dioxide gas into the water, thestep of agitating the water beginning about 0.5 seconds after beginningthe step of introducing carbon dioxide gas into the carbonation chamber;and dispensing carbonated water from the carbonation chamber.
 38. Themethod according to claim 37, further comprising: selecting one of afirst carbonation level and a second carbonation level.
 39. The methodaccording to claim 38, wherein when the first carbonation level isselected, the step of agitating the water continues for about 7 seconds,and when the second carbonation level is selected, the step of agitatingthe water continues for about 4 seconds.
 40. The method according toclaim 37, further comprising: before the step of dispensing carbonatedwater, relieving gas pressure from the carbonation chamber.
 41. Themethod according claim 40, further comprising: silencing the gaspressure being relieved from the carbonation chamber.
 42. The methodaccording to claim 41, wherein the step of relieving gas pressure stautsabout 2 seconds after the step of agitating the water completes.
 43. Themethod according to claim 37, wherein the water is introduced into thecarbonation chamber vertically above where the water is dispensed fromthe carbonation chamber.
 44. A method for carbonating we comprising thesteps of: partially filling a rectangular carbonation chamber with waterto a pre-determined level; introducing carbon dioxide gas into thecarbonation chamber above the water; agitating the water to mix carbondioxide gas into the water; relieving gas pressure from the carbonationchamber; silencing the gas pressure being relieved from the carbonationchamber; and dispensing carbonated water from the carbonation chamber.45. The method according to claim 44, maintaining the pressure of thecarbon dioxide gas in the carbonation chamber while agitating the water.46. The method according to claim 44, wherein the step of partiallyfiling a carbonation chamber introduces the water into an upper portionof the carbonation chamber.
 47. The method according to claim 44,wherein the water is introduced into the carbonation chamber verticallyabove where the water is dispensed from the carbonation chamber.
 48. Themethod according to claim 44, further comprising: venting air from thecarbonation chamber while introducing carbon dioxide gas; and permittingair to enter the carbonation chamber while dispensing carbonated waterfrom the carbonation chamber.
 49. The method according to claim 44,further comprising: venting excess water from the carbonation chamber;and mixing the vented excess water and the relieved gas during the stepof silencing.
 50. The method according to claim 44, further comprising:selecting one of a first carbonation level and a second carbonationlevel.
 51. The method according to claim 44, wherein the step ofagitating the water begins about 0.5 seconds after beginning the step ofintroducing carbon dioxide gas into the carbonation chamber.
 52. Acarbonation apparatus comprising: a rectangular carbonation chamber; asource of water; a water inlet valve connecting the source of water tothe carbonation chamber; a source of carbon dioxide gas; a carbondioxide inlet valve connecting the source of carbon dioxide gas to thecarbonation chamber; a rotatable mixer within the carbonation chamber; agas exhaust valve connected to the carbonation chamber; a gas exhaustsilencer connected to the gas exhaust valve; and a carbonated waterdispensing valve connected to the carbonation chamber.
 53. Thecarbonation apparatus according to claim 52, wherein the gas exhaustsilencer reduces the speed of gas being relieved from the carbonationchamber.
 54. The carbonation apparatus according to claim 52, whereinthe gas exhaust silencer comprises: a housing having at least one inletand one outlet, the housing having an internal cavity with a filtertherein, the into cavity being in communication with a first inlet, thefirst inlet receiving gas being relieved from the carbonation chamber,the outlet being in communication with the first inlet and receiving gasafter the gas passes through the filter.
 55. The carbonation apparatusaccording to claim 54, wherein the housing has at least two inlets, asecond inlet receiving water vented from the carbonation chamber, thevented water being mixed with the relieved gas, the outlet receiving themixed water and gas.
 56. The carbonation apparatus according to claim52, wherein the gas exhaust silencer comprises: a housing having a gasinlet, a water inlet, an outlet and two internal cavities, a firstcavity being communication with the gas inlet and a second cavity beingcommunication with the water inlet, both cavities being in communicationwith the outlet, the gas inlet receiving gas being relieved from thecarbonation chamber, the water inlet receiving water being vented fromthe carbonation chamber, the outlet receiving both water and gas. 57.The carbonation apparatus according to claim 56, wherein the housing hasa filter therein, the filter being positioned at least within the secondcavity.